Method Of Forming An Absorbent Structure

Abstract

A liquid absorbent structure is made by dry laying a fibrous web having incorporated therein a superabsorbent material, and applying an aqueous composite stabilizer to at least one surface of the web. The aqueous composite stabilizer imparts integrity to the resulting structure without substantially impairing the effectiveness of the superabsorbent material to absorb liquid while forming the absorbent structure without removing the water from aqueous composite stabilizer or drying out the absorbent structure. The absorbent composite absorbs the water from the aqueous composite stabilizer. The absorbent composite comprises about 70% by weight of a superabsorbent material.

Description

[0001]The present application is a Divisional application and claims priority to U.S. patent application Ser. No. 14 / 186,305, entitled “Method of Forming An Absorbent Structure” and filed on Feb. 21, 2014, which claims priority to U.S. Provisional Application No. 61 / 884,184, entitled “Method of Forming An Absorbent Structure” and filed on Sep. 30, 2013, the contents of which are hereby incorporated by reference in a manner consistent with the present application.BACKGROUND[0002]Absorbent composites containing high levels of superabsorbent polymer exhibit increased problems maintaining composite integrity. This is due to insufficient fiber to contain and restrict the mobility and migration of superabsorbent material in the composite. This is a problematic situation, since there is a very strong motivation to design and produce thin, flexible, comfortable absorbent products. The lack of integrity in an absorbent composite also challenges the ability to manufacture products with high s...

AI Technical Summary

Benefits of technology

The patent describes a way to make a absorbent structure for a diaper without needing to dry it out. This is done by using a special stabilizer made of water and a chemical called a stabilizing component. The absorbent material in the structure soaks up the water from the stabilizer. This method helps to avoid issues that arise when the absorbent is dried out, such as mold or uneven absorption. The absorbent structure contains a high amount of superabsorbent material, which is important for optimal absorbency.

Problems solved by technology

Absorbent composites containing high levels of superabsorbent polymer exhibit increased problems maintaining composite integrity.

This is due to insufficient fiber to contain and restrict the mobility and migration of superabsorbent material in the composite.

This is a problematic situation, since there is a very strong motivation to design and produce thin, flexible, comfortable absorbent products.

The lack of integrity in an absorbent composite also challenges the ability to manufacture products with high superabsorbent material composites at fast line speeds.

In addition, upon initial product use, migration of the superabsorbent material in the product can compromise fluid performance and product comfort during extended use including issues such as sagging and drooping.

However, embossing or debulking damages the superabsorbent, compromising fluid properties of the absorbent product.

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